Effects of simultaneous ultrasonic vibration of tool and addition of carbon nanotube into the dielectric in EDM process on machining outputs and surface integrity of Ti-6Al-4V alloy

Abstract

This study is an attempt to add multi-wall carbon nanotubes to the dielectric used in the EDM and ultrasonic assisted EDM process in order to assess its performance at the time of machining the Ti-6Al-4V alloy by means of copper electrodes. The effects of adding CNT powders to the dielectric and applying ultrasonic vibration to tool on the material removal rate, tool wear ratio and surface integrity of the work-piece have investigated. The results show that the addition of multi-walled carbon nanotubes in dielectric has significant effect on machining stability and reduced material removal rate and tool wear ratio, too. The amount of MRR and TWR has been increased by ultrasonic assisted EDM process. The outcomes of the study demonstrated that the addition of CNT particle decreases the surface roughness and vibration of tool with ultrasonic frequency deteriorates surface roughness. Ultrasonic vibration of tool and the addition of CNT powder to dielectric reduced the length and the width of surface cracks and the depth of metal altered zone.